Senior Process Engineer

Leidos; Huntsville (AL); On-site; USD 116,000 - 210,000; Full time

Job summary

Leidos is seeking a Senior Process Engineer in Huntsville, AL to lead and implement state-of-the-art electronics manufacturing capabilities. You will drive PCBA assembly, SMT, conformal coating, inspection, and automated test operations from layout to final integration.

You will collaborate with Manufacturing, Industrial, Quality, Facilities, and Operations teams to optimize workflows, improve equipment utilization, and ensure on-time delivery while mentoring junior engineers.

Qualifications

• Requires a BS degree with 12–15 years of PCBA/process development experience.
• U.S. citizenship and ability to obtain final Secret clearance.
• Experience in PCBA manufacturing and DFM optimization.
• Resident of Huntsville, AL or willing to relocate to Huntsville, AL.

Responsibilities

• Co-lead the manufacturing engineering team supporting PCBA assembly and related processes.
• Drive continuous improvement to increase yield, throughput, and quality across the production line and specialized equipment.
• Monitor manufacturing KPIs (yield, first-pass yield, cycle time, scrap, escapes) to predict trends and drive proactive process changes.
• Perform DFM/DFA reviews on new product introductions and design changes, providing feedback to design engineering.
• Develop, document, and implement new manufacturing processes, work instructions, and process control plans.
• Identify, specify, and justify capital equipment for PCBA assembly, conformal coating, and related processes.
• Support root cause analysis, corrective action, and disposition of manufacturing and quality nonconformances.
• Partner with quality, production control, and design teams to meet delivery schedules and customer quality requirements.
• Support quality engineering in process development and onsite audits
• Establish and monitor quality objectives of the production process
• Mentor and develop junior engineers in process development, root cause analysis,and mitigation

Skills

DFM

Lean principles

Root cause analysis

PCBA manufacturing

Process development

Team mentorship

U.S. Citizenship

Education

BS degree with 12–15 years experience

Masters degree with 10–12 years experience

Tools

IPC standards J-STD-001

IPC-A-610

Costpoint

Windchill

Aegis Factory Logix MES

Job description

Looking for an opportunity to make an impact?

At Leidos, we deliver innovative solutions through the efforts of our diverse and talented people who are dedicated to our customers’ success. We empower our teams, contribute to our communities, and operate sustainably. Everything we do is built on a commitment to do the right thing for our customers, our people, and our community. Our Mission, Vision, and Values guide the way we do business.

Your greatest work is ahead!

We are seeking a motivated, hands-on Senior Process Engineer to play a key role in the development, implementation, and ramp-up of a new, state-of-the-art electronics manufacturing facility. This position offers an exciting opportunity to help shape manufacturing capabilities from the ground up, supporting facility layout development, equipment installation, commissioning, and process optimization across Surface Mount Technology (SMT), conformal coating, inspection, and automated test operations. The candidate will collaborate with Manufacturing Engineering, Industrial Engineering, Quality, Facilities, and Operations teams to establish efficient production workflows, optimize equipment utilization, and ensure seamless transitions from PCBA manufacturing through subassembly and final integration.

If this sounds like the kind of environment where you can thrive, keep reading!

Leidos Defense Systems Sector / Manufacturing provides a diverse portfolio of systems, solutions, and services covering land, sea, air, space, and cyberspace for customers worldwide. Solutions for Defense include enterprise and mission IT, large-scale intelligence systems, command and control, geospatial and data analytics, cybersecurity, logistics, training, and intelligence analysis and operations support. Our team is solving the world’s toughest security challenges for customers with “can’t fail” missions.

Primary Responsibilities

• Co-lead and develop the manufacturing engineering team supporting PCBA assembly and complimentary processes such as selective solder, press-fit, conformal coating, board washing, etc..


• Drive continuous improvement projects to increase yield, throughput, and quality across the production line and specialized equipment.


• Monitor manufacturing KPIs (yield, first-pass yield, cycle time, scrap, escapes) to predict trends and drive proactive process changes.


• Perform DFM/DFA reviews on new product introductions and design changes, providing feedback to design engineering.


• Develop, document, and implement new manufacturing processes, work instructions, and process control plans.


• Identify, specify, and justify capital equipment for PCBA assembly, conformal coating, and related manufacturing processes.


• Support root cause analysis, corrective action, and disposition of manufacturing and quality nonconformances.


• Partner with quality, production control, and design teams to meet delivery schedules and customer quality requirements.


• Support quality engineering in process development and onsite audits


• Establish and monitor quality objectives of the production process


• Mentor and develop junior engineers in process development, root cause analysis,and mitigation

Basic Qualifications

• Requires a BS degree and 12-15 years of prior relevant experience or Masters with 10-12 years of prior relevant experience. In lieu of a degree, a highschool diploma/GED with 15 years of experience will be considered


• Must be a U.S. Citizen and be able to obtain/maintain a finalSecret Clearance


• Previous experience working in PCBA manufacturing and process development


• Strong background in Design for Manufacturability (DFM) to optimize product designs for production efficiency.


• Candidate must be a resident of Huntsville, Alabama or be willing to relocate to the Huntsville, Alabama area.

Preferred Qualifications

• Familiarity with IPC requirements (J-STD-001 and IPC-A-610)


• Experience with electronics used on launch vehicles, targets, or missile components such as PCBAs, cable harnesses, or electro-mechanical assemblies


• Experience with Costpoint Material Planning software and/or Windchill product lifecycle management software is a plus.


• Experience working in a mid to high volume manufacturing environment


• Ability to provide Rough Order of Magnitude (ROM) estimates, Basis of Estimate (BOE) documents, and other information to support proposal efforts


• Demonstrated success in implementing lean principles to reduce waste and improve efficiency.


• Experience in using Manufacturing Execution Systems (MES) such as Aegis Factory Logix is also a plus.


• Hands-on experience with PCBA automation equipment, such as SMT mounters, selective solder, board wash, press-fit, AOI, and general soldering equipment.

If you're looking for comfort, keep scrolling. At Leidos, we outthink, outbuild, and outpace the status quo - because the mission demands it. We're not hiring followers. We're recruiting the ones who disrupt, provoke, and refuse to fail. Step 10 is ancient history. We're already at step 30 - and moving faster than anyone else dares.

Original Posting:

November 6, 2026

For U.S. Positions: While subject to change based on business needs, Leidos reasonably anticipates that this job requisition will remain open for at least 3 days with an anticipated close date of no earlier than 3 days after the original posting date as listed above.

Pay Range:

Pay Range $116,350.00 - $210,325.00

The Leidos pay range for this job level is a general guideline only and not a guarantee of compensation or salary. Additional factors considered in extending an offer includes (but are not limited to) responsibilities of the job, education, experience, knowledge, skills, and abilities, as well as internal equity, alignment with market data, applicable bargaining agreement (if any), or other law.

About Leidos

Leidos is an industry and technology leader serving government and commercial customers with smarter, more efficient digital and mission innovations. Headquartered in Reston, Virginia, with 47,000 global employees, Leidos reported annual revenues of approximately $16.7 billion for the fiscal year ended January 3, 2025. For more information, visit www.Leidos.com.

Pay and Benefits

Pay and benefits are fundamental to any career decision. That's why we craft compensation packages that reflect the importance of the work we do for our customers. Employment benefits include competitive compensation, Health and Wellness programs, Income Protection, Paid Leave and Retirement. More details are available at www.leidos.com/careers/pay-benefits.

Securing Your Data

Beware of fake employment opportunities using Leidos’ name. Leidos will never ask you to provide payment-related information during any part of the employment application process (i.e., ask you for money), nor will Leidos ever advance money as part of the hiring process (i.e., send you a check or money order before doing any work). Further, Leidos will only communicate with you through emails that are generated by the Leidos.com automated system - never from free commercial services (e.g., Gmail, Yahoo, Hotmail) or via WhatsApp, Telegram, etc. If you received an email purporting to be from Leidos that asks for payment-related information or any other personal information (e.g., about you or your previous employer), and you are concerned about its legitimacy, please make us aware immediately by emailing us at [e-mail].

If you believe you are the victim of a scam, contact your local law enforcement and report the incident to the U.S. Federal Trade Commission.

Commitment to Non-Discrimination

All qualified applicants will receive consideration for employment without regard to sex, race, ethnicity, age, national origin, citizenship, religion, physical or mental disability, medical condition, genetic information, pregnancy, family structure, marital status, ancestry, domestic partner status, sexual orientation, gender identity or expression, veteran or military status, or any other basis prohibited by law. Leidos will also consider for employment qualified applicants with criminal histories consistent with relevant laws.